Differential: Removal & Installation Pontiac Aztek I

REMOVAL & INSTALLATION

Note. Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. DO NOT use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

Removal

1. Set the parking brake. Raise and support the vehicle. Remove the right rear tire/wheel assembly. Place a drain pan beneath the differential. Remove the differential drain plug. see scheme 1 Drain the rear differential gear oil. Disconnect the electrical connector from the clutch pump check valve. see scheme 1 Remove the right rear axle shaft. See appropriate AXLE SHAFTS - REAR article in DRIVELINE/AXLE. Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article in DRIVELINE/AXLE.
2. Place an adjustable support beneath the torque tube. Loosen, but DO NOT remove the torque tube-to-bracket through-bolt and nut. Remove torque tube bracket-to-body bolts. Remove the differential carrier-to-cradle mounting bolts, nuts, washers and mounts from the differential. During the removal of the axle shaft, the differential output shaft may become disengaged from the differential. If this occurs, firmly grasp and separate the output shaft from the axle shaft. Align the splines on the output shaft to the differential and reposition the output shaft to the differential.
3. While simultaneously moving the differential assembly to the right side of the vehicle, disengage the left axle shaft from the differential. Remove the rear differential and torque tube as an assembly. Remove the torque tube from the differential. See «TORQUE TUBE ASSEMBLY»(ref-167081-S18246061102004100500000).

Installation

1. Install the torque tube to the differential. See «TORQUE TUBE ASSEMBLY»(ref-167081-S18246061102004100500000). Install the rear differential and torque tube assembly to the suspension cradle. Simultaneously guide the left axle shaft onto the differential output shaft while positioning the differential assembly to the suspension cradle. Place an adjustable support under the torque tube. Ensure that the left axle shaft is fully engaged to the differential output shaft. Install the differential carrier mounts, washers, bolts and nuts to the differential.
2. Tighten the differential carrier-to-cradle mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Install the torque tube bracket-to-body bolts. Tighten the torque tube bracket-to-body bolts to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Tighten the torque tube-to-bracket through-bolt and nut to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000).
3. Install the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article under DRIVELINE/AXLE. Install the right axle shaft. See appropriate AXLE SHAFTS - REAR article in DRIVELINE/AXLE. Install the right rear tire and wheel assembly. Tighten bolts to specifications. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Install the differential drain plug and gasket to the differential. Tighten the drain plug to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000).
4. Remove the differential fill plug. see scheme 1 Fill the axle with synthetic gear oil. Inspect the differential oil level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. See «LUBRICATION»(ref-167081-S31301081902004100500000). Fill differential as necessary. Install the differential fill plug and gasket. Tighten the fill plug to specifications. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000).
5. Connect the electrical connector to the clutch pump check valve. Remove the adjustable support from the torque tube. Lower the vehicle. Operate the vehicle making tight left, then right turns in order to engage the all-wheel-drive system and distribute the gear oil throughout the differential. Raise and support the vehicle. Remove the differential fill plug. Fill the axle with synthetic gear oil. Inspect the differential oil level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. Install the differential fill plug and gasket. Tighten the fill plug to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Lower the vehicle.

1. Raise and support the vehicle. Support the front of the differential with a suitable stand. Loosen, but do not remove, the torque tube-to-bracket through bolt and nut. see scheme 1
2. Remove the cradle-to-differential mounting bolts, nuts, washers, and bushings from the differential. (Scheme 1) Raise the stand slightly in order to gain access to the differential-to-cradle bushings. Remove the differential-to-cradle bushings. (Scheme 1)

Scheme 1

1. Install the differential-to-cradle bushings. (Scheme 1) Lower and remove the jack stand.
2. Install the cradle-to-differential mounting bolts, bushings, washers, and nuts to the differential. Tighten the bolts and nuts to specifications. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000).
3. Secure the torque tube-to-bracket through bolt and nut. Tighten the bolt and nut to specifications. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Lower the vehicle.

Drain the differential lubricant. See LUBRICATION. Disconnect the clutch pump check valve electrical connector. Remove the clutch pump check valve mounting bolts. see scheme 1 Remove the clutch pump check valve by carefully pulling straight out of the differential carrier. Remove the "O" ring seals from the valve. The "O" ring seals may be reused if not cut or damaged. If reinstalling original valve, inspect for damaged, loose, or missing pick up screen, damaged or missing "O" rings, damaged electrical connector, or oil passages restricted by dirt or debris.

Note. Inspect the clutch pump check valve "O" ring seals to ensure they are not cut or damaged. Replace cut or damaged "O" ring seals with NEW seals.

1. Lubricate the "O" ring seals with Synthetic Gear Oil (12378514 for United States or 88901045 for Canada) or equivalent. Install the "O" ring seals to the valve. Install the clutch pump check valve to the differential carrier by carefully pushing the valve straight in until fully seated.
2. Install the clutch pump check valve mounting bolts. see scheme 1 Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Connect the clutch pump check valve electrical connector. Inspect differential fluid level. See «LUBRICATION»(ref-167081-S31301081902004100500000). Fill differential as necessary.

Note. The internal components of the torque tube assembly cannot be serviced separately. If corrosion exists that cannot be polished off, or there is excessive scoring or wear, the torque tube must be replaced as a complete assembly.

Drain differential. Remove the torque tube assembly. See TORQUE TUBE ASSEMBLY. Remove the drive pinion housing oil seal, and discard. see scheme 1 Inspect the sealing surface of the drive shaft contained inside the torque tube. Polish corrosion off with a crocus cloth.

Note. Required Tools: Seal Installer (J-44915).

Lubricate the NEW pinion housing assembly "O" ring and oil seal with Synthetic Gear Oil (12378514 for United States; 88901045 for Canada) or equivalent. Use the Seal Installer in order to install the NEW oil seal to the drive pinion housing. Install the torque tube assembly. See TORQUE TUBE ASSEMBLY . Tighten bolts to specification. See TORQUE SPECIFICATIONS . Inspect the differential carrier lubricant level. See LUBRICATION .

1. Drain the differential lubricant. See «LUBRICATION»(ref-167081-S31301081902004100500000). Remove the torque tube assembly. See «TORQUE TUBE ASSEMBLY»(ref-167081-S18246061102004100500000). Remove the drive pinion oil seal from the drive pinion housing and discard. see scheme 1
2. Remove the pinion housing-to-differential bolts. Remove the drive pinion and housing assembly. Carefully remove the drive pinion housing shim from the differential. see scheme 1
3. Remove the O-ring seal from the drive pinion housing and discard.

Note. Required Tools: Seal Installer (J-44915).

1. Lubricate the O-ring seal with synthetic gear oil GM P/N United States 12378514 Canada P/N 88901045 or equivalent. Using the Seal Installer, install the oil seal to the drive pinion housing. Install the O-ring seal to the drive pinion housing.
2. Carefully install the drive pinion housing assembly and shim to the differential carrier. see scheme 1 Install the pinion housing-to-differential mounting bolts. Tighten the bolts specifications. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000).
3. Lubricate the sealing surfaces of the drive pinion oil seal with synthetic gear oil GM P/N United States 12378514 Canada P/N 88901045 or equivalent. Install the torque tube assembly. See «TORQUE TUBE ASSEMBLY»(ref-167081-S18246061102004100500000). Fill the differential with synthetic gear oil. See «LUBRICATION»(ref-167081-S31301081902004100500000).

Note. Required Tools: Output Shaft Seal Installer (J-44809).

Note. Inspect the sealing surface of the axle shaft inner tri-pot housing to ensure it is free of corrosion. Use a crocus cloth in order to remove any light corrosion and clean the sealing surface with denatured alcohol, or equivalent.

Raise and support the vehicle. Remove the left rear or right rear tire and wheel assembly. Remove the left axle shaft or right axle shaft. See appropriate AXLE SHAFT - REAR article under DRIVELINE/AXLES. Remove the differential output shaft oil seal. see scheme 1 Do not damage the differential sealing surfaces. Using the Output Shaft Seal Installer, install the left or right axle shaft oil seal. Lubricate the axle shaft sealing surfaces of the oil seal with synthetic gear oil GM P/N 12378514 Canadian P/N 88901045 or equivalent. Install the right or left axle shaft. See appropriate AXLE SHAFT - REAR article under DRIVELINE/AXLES. Install the right or left rear tire and wheel assembly. Tighten bolts to specifications. See TORQUE SPECIFICATIONS. Inspect the differential lubricant level. See LUBRICATION. Lower the vehicle.

Note. The drive pinion oil seal must be replaced whenever the torque tube is removed.

1. Raise and support the vehicle. Position a jack stand under the front of the rear differential and firmly secure the differential to the jack. Remove the front drive shaft. See appropriate DRIVE SHAFT & UNIVERSAL JOINTS article under DRIVELINE/AXLE.
2. Remove the bolts from the torque tube bracket. see scheme 1 Loosen, but DO NOT remove, the torque tube-to-bracket through-bolt and nut. Remove the torque tube-to-differential bolts. Pull the torque tube toward the front of the vehicle in order to disengage the torque tube from the differential pinion shaft. Remove the torque tube from the differential. Remove the oil seal from the drive pinion housing and discard.

Note. Required Tools: Seal Installer (J-44915).

1. Using Seal Installer, install a NEW oil seal to the drive pinion housing. see scheme 1 Align the splines on the torque tube shaft to the differential pinion shaft. Install the torque tube to the differential.
2. Install the bolts to the torque tube bracket. Tighten the torque tube bracket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Tighten the torque tube-to-bracket through-bolt and nut to specification. Install the torque tube-to-differential carrier bolts. Tighten the bolts to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000).
3. Install the front drive shaft. See appropriate DRIVE SHAFT & UNIVERSAL JOINTS article under DRIVELINE/AXLES. Tighten the mounting bolts to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000). Remove the jack stand from under the front of the rear differential. Lower the vehicle.

Raise and support the vehicle. Place a jack stand under the torque tube. Remove the torque tube-to-bracket through-bolt, nut, washers and spacers. Remove the torque tube bracket-to-body bolts. see scheme 1 Lower the jack stand slightly in order to gain access to the torque tube bracket. Remove the torque tube-to-bracket through bolt, nut, washers, and spacers. Remove the torque tube bracket.

Note. DO NOT fully tighten the torque tube-to-bracket through-bolt. Hand tighten only until the bracket is secured to the vehicle body.

1. Install the torque tube bracket. Install the torque tube-to-bracket through-bolt, nut, washers and spacers. Raise the jack stand in order to install the torque tube mounting bracket to the vehicle body.
2. Install the torque tube bracket-to-body bolts. Tighten the torque tube mounting bracket-to-body bolts to specification. Tighten the torque tube-to-bracket through-bolt to specification. See «TORQUE SPECIFICATIONS»(ref-167081-S14998983012004100500000) . Remove the jack stand. Lower the vehicle.

Raise and support the vehicle. Remove the vent hose clamp from the vent hose. Release the grommet securing the vent hose to the vehicle underbody. Remove the vent hose from the differential assembly vent tube by carefully twisting the hose. see scheme 1 Install the vent hose to the differential assembly. Install the vent hose clamp to the vent hose. Secure the grommet on the vent hose to the vehicle underbody. Lower the vehicle.